Mitsubishi Montero (1991+). Manual - part 1

3.0L V6 - VINS [B,C,S] 



1991 Mitsubishi Montero

         1991 ENGINES

         Mitsubishi 3.0L V6

         Montero, Pickup, 3000GT

         * PLEASE READ THIS FIRST *

NOTE:    For engine repair procedures not covered in this article,

         see ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION  article

         in the GENERAL INFORMATION section.

         ENGINE IDENTIFICATION

         Engine may be identified by using Vehicle Identification

Number (VIN) stamped on a metal pad, located near lower left corner of

windshield. The eighth character identifies the engine model.

         Engine model number is stamped on front upper edge of

cylinder block (below cylinder head) or on vehicle information plate

on firewall. Engine serial number is stamped near the engine model

number.

ENGINE IDENTIFICATION CODES TABLE

Application            Engine Model         Engine Code

3.0L V6 SOHC

 Montero ...............  6G72  ....................  S

 Pickup ................  6G72  ....................  S

3.0L V6 DOHC

 3000GT

  Non-Turbo ............  6G72  ....................  B

  Turbo ................  6G72  ....................  C

         ADJUSTMENTS

         VALVE CLEARANCE ADJUSTMENT

NOTE:    Hydraulic lash adjusters are set into rocker arms (SOHC) or

         cylinder head (DOHC). No adjustment is required.

         REMOVAL & INSTALLATION

NOTE:    For reassembly reference, label all electrical connectors,

         vacuum hoses and fuel lines before removal. Also place

         mating marks on engine hood and other major assemblies

         before removal.

         FUEL PRESSURE RELEASE

         Perform these steps to release fuel system pressure:

      *  Disconnect fuel pump harness connector at fuel tank.

      *  Start engine. After it stalls, turn ignition switch to OFF

         position.

      *  Disconnect battery (-) terminal, and reconnect fuel pump

         harness connector.

      *  Wrap shop towels around fuel return and high pressure hoses

         to prevent fuel splashing on engine. Disconnect fuel return

         hose and high pressure fuel hose to drain any residual fuel.

         ENGINE

         Removal (Montero & Pickup)

         1) Remove hood. Drain cooling system, and remove radiator.

Remove skid plate and splash shields. Release fuel system pressure.

See FUEL PRESSURE RELEASE under REMOVAL & INSTALLATION. Disconnect

negative battery cable.

         2) Remove air cleaner ducts. Remove accessory drive belts.

Remove and support A/C compressor and power steering pump. DO NOT

disconnect hoses from compressor or pump. Disconnect oil cooler hoses.

Cover fuel hose using shop towel, and disconnect high pressure fuel

hose and "O" ring. Remove fuel return hose.

         3) Label and disconnect all vacuum hoses. Disconnect cooling

system hoses. Label and disconnect all electrical connections from

engine. Remove heat shield from motor mounts. Remove motor mount

bolts. Ensure all hoses and wires are disconnected and set aside.

         4) Disconnect exhaust pipe from exhaust manifolds. Remove

starter. Attach engine hoist to engine. Support transmission.

Disconnect engine from transmission. See appropriate article in

CLUTCHES or TRANSMISSION SERVICING. Remove engine.

         Installation (Montero & Pickup)

         To install, reverse removal procedure. Install new "O" ring

on fuel line. Install new exhaust gaskets and nuts. See TORQUE

SPECIFICATIONS (MONTERO & PICKUP) table at end of article. Adjust

fluid levels.

         Removal (3000GT)

         1) Release fuel pressure. See FUEL PRESSURE RELEASE under

REMOVAL & INSTALLATION. Remove hood. Remove cruise control vacuum pump

and linkage. On turbo models, remove necessary turbo air intake hoses

and pipes. On all other models, remove air cleaner hoses.

         2) On all models, drain cooling system. Drain engine oil and

transaxle oil. Remove heater hoses and radiator hoses. Remove

transaxle assembly. See appropriate article in CLUTCHES or

TRANSMISSION SERVICING.

         3) Remove radiator. Label and disconnect all vacuum hoses.

Label and disconnect all electrical connections and harnesses from

engine. Remove accessory drive belts.

         4) Remove and support A/C compressor and power steering pump.

DO NOT disconnect hoses from compressor or pump. Cover fuel hose using

shop towel, and disconnect high pressure fuel hose and "O" ring.

Remove fuel return hose.

         5) On turbo models, disconnect oil cooler and vacuum hoses.

On all models, remove motor mount bolts and brackets. Ensure all hoses

and wires are disconnected and set aside. Attach engine hoist to

engine. Remove engine.

         Installation

         To install, reverse removal procedure. Install new "O" ring

on fuel line. Install new exhaust gaskets and nuts. See TORQUE

SPECIFICATIONS (3000GT) table at end of article. Adjust fluid levels.

         UPPER INTAKE MANIFOLD

         Removal (Montero & Pickup)

         1) Remove air intake hose. See Fig. 1. Remove accelerator

cable adjusting bolts. On models equipped with automatic transmission,

remove throttle control cable. On all models, remove accelerator

cable. Label and disconnect all vacuum hoses from throttle body and

upper intake manifold.

         2) Disconnect O2 sensor connector. Remove EGR pipe and

gasket. Remove ignition coil. Remove engine oil filler neck bracket.

Remove throttle body, leaving coolant hoses connected. Remove throttle

body gasket. Remove upper intake manifold plenum mounting bolts and

nuts.

         3) If necessary, remove EGR valve and pipe. Remove upper

intake manifold plenum brackets. Remove upper intake manifold and

gasket.

         Inspection & Installation (Montero & Pickup)

         Clean all gasket mating surfaces. Inspect for damage and

cracks on all mounting surfaces. To install, reverse removal procedure

using new gaskets. Tighten bolts and nuts to specification. See TORQUE

SPECIFICATIONS (MONTERO & PICKUP) table at end of article.

Fig. 1:  Exploded View of Upper Intake Manifold & Components (DOHC)

Courtesy of Mitsubishi Motor Sales of America, Inc

Fig. 2:  View of Upper Intake Manifold & Components (DOHC Turbo, SOHC)

Courtesy of Mitsubishi Motor Sales of America, Inc

         Removal (3000GT)

         1) Remove air intake hose. Remove throttle body and gasket

with control cables and coolant and vacuum hoses attached. See  Fig. 2.

         2) Remove EGR and EGR pipe (if equipped). Disconnect power

brake hose. Label and disconnect vacuum hoses and electrical

connections. Remove upper intake manifold plenum retaining bracket(s),

mounting bolts and nuts. Remove upper intake manifold.

         Inspection & Installation (3000 GT)

         Clean all gasket mating surfaces. Inspect for damage and

cracks on all mounting surfaces. To install, reverse removal procedure

using new gaskets. Install throttle body gasket with projection on

gasket facing upward beyond throttle body mounting surface. Tighten

bolts and nuts to specification. See TORQUE SPECIFICATIONS (3000GT)

table at end of article.

         LOWER INTAKE MANIFOLD

CAUTION:  Fuel system is under pressure. Fuel pressure must be